Control for and automatic washer with spray pretreatment

ABSTRACT

This invention relates a control for an automatic washer incorporating a spray pretreatment or stain care cycle. In order to manage the occurrence of the condition of suds lock, the state of the washing machine related to the suds lock condition during spray pretreatment is determined by one or more of a number of methods. With this information concerning the state of the spray pretreatment process, the occurrence of suds lock can be ascertained and the cycle can be controlled accordingly to minimize negative effects resulting from a prolonged suds lock condition. Additionally, with certain information related to the occurrence of suds lock, steps can be taken during the spray pretreatment portion of the cycle to avoid the condition of suds lock altogether. Using the same primary process for measuring suds lock, load size can also be ascertained. Information about load size can be used to control the wash cycle.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to automatic washers, either of thefront-loading or top-loading loading types, and more particularly to animproved washing system and control therefor.

[0002] Automatic clothes washers generally include fluid handlingsystems for filling a washer tub with a wash fluid consisting of a waterand detergent solution, tumbling or agitating a wash load of fabrics fora period of time, then draining the wash fluid from the tub. A portionof the washing part of the cycle may include a spray treatment orpretreatment of the fabrics while the basket is spinning. A subsequentrinse with fresh water and draining of the rinse water are alsoprovided. All or part of the rinse cycle may include a spray rinse ofthe fabrics while the basket is spinning at high speed.

[0003] Spray treatment of fabrics during the wash cycle therefore isknown. Spray treatment may be desirable in a clothes washer because ofknown benefits such as improved washing performance and reduced energyand water usage. An example of a clothes washer having spray treatmentis disclosed in U.S. Pat. No. 5,271,251 for example, assigned to theassignee of the present invention. In this example, however, a probesensor provides a signal for the purpose of maintaining a predeterminedwater level during recirculation. Alternatively, a pressure dome ortemperature thermistor may be used to detect the water level and adetermination may be made for the level of water to be used in thefollowing swirl portion of the cycle. However, there is no determinationmade of the amount of fabric load contained within the washer using theon or off times of the inlet valve or valves or the information providedby the pressure sensor.

[0004] There are known disadvantages to spray treatment as well. Oneundesirable condition which has been found to occur during a spraypretreatment portion of the wash cycle is ‘suds lock’. When thiscondition occurs, contact of the fluid with the spinning basket acts tofurther increase the amount of suds which thus raises the height of thesudsy fluid toward the basket. The eventual result of this unstableprocess is that suds build up beyond the bottom of the basket and climbbetween the sides of the basket and tub. This large amount of sudsacting between the spinning basket and the fixed tub produces asignificant drag force on the basket. This drag force is large enough tocause the clutch to slip and thus causing the basket to slow downconsiderably. This slipping of the clutch due to excessive suds betweenthe spinning basket and the tub is called ‘suds lock’.

[0005] Certain combinations of environmental factors have been found toincrease the likelihood of suds lock. Such combinations of very smallloads or no load, very large doses of detergent, liquid detergent, typeof detergent and soft water have been found to increase the formation ofsuds during the spray pretreat cycle. Also, if the means by which theamount of water controlled during the spray pretreatment cycle is notrobust, suds lock may be more likely. To guard against both worst caseconditions or machine degradation over time, a control for sensing sudslock and controlling the machine based on suds lock information isdesirable.

[0006] U.S. Pat .No. 4,784,666, assigned to the assignee of the presentapplication, discloses a high performance washing process for verticalaxis automatic washers which includes the recirculation of wash fluidprior to the agitate portion of the wash cycle. That patent describes,as a particular embodiment of the invention, to load a charge ofdetergent into the washer along with a predetermined amount of water,preferably prior to admitting a clothes load into the basket to assurethat the concentrated detergent solution will initially be held in asump area of the wash tub so that the detergent will be completelydissolved or mixed into a uniform solution before being applied to theclothes load. It is also suggested that the addition of an anti foamingagent may be desirable. No particular arrangement is provided for mixingthe detergent and water to provide a uniform solution, nor is anyparticular means described for assuring that the amount of wash liquidwithin the tub during the spin wash portion of the wash cycle is anappropriate amount which is slightly in excess of the saturation levelfor the clothes load.

[0007] U.S. Pat. Nos. 5,219,370 and 5,233,718, assigned to the assigneeof the present invention, disclose variations on a high performancewashing process for vertical or horizontal axis automatic washers whichinclude the recirculation of wash fluid prior to the agitate portion ofthe wash cycle or other washing or rinsing steps. The primary means forcontrolling water input into the systems is to detect water level usinga liquid level sensor. It is suggested that a pressure dome sensor maybe used to detect an oversudsing condition, however this would beperformed in conjunction with usage of the liquid level sensor, which isnot provided for in the present invention. These patents allow for thepossibility of indirectly inferring the water level in the tumbleportion of the cycle based on the sensed level of detergent liquor inthe pretreatment portion, unlike the present invention which determinesthe amount of clothes load and possibility of suds lock.

SUMMARY OF INVENTION

[0008] The present invention provides a control for sensing the state ofthe washing machine during a pretreatment cycle having a combined sprayand high speed spin. During such a pretreatment cycle the washer issusceptible to the possible occurrence of a suds lock condition, whichmay be detected and handled by the present invention. This can beaccomplished by a variety of sensing techniques, through which thepossible or imminent occurrence of suds lock can be determined orinferred, including sensing the condition of the wash liquid or thewashing machine components. A suds lock condition may even beanticipated and avoided by the present invention. Further, by knowingthat a suds lock condition is occurring or is likely to occur, the spraypretreatment portion of the wash cycle can be preterminated and the restof the cycle can be continued. Alternatively, adding of water may bediscontinued. By following a suds lock condition immediately with adeepfill of the tub of the automatic washer, suds buildup within thebasket can be minimized.

[0009] By using the same technique of measuring suds lock, the size ofthe load can also be ascertained. This information can thus be appliedto control the rest of the cycle. For example, the automatic deepfillwater level and relative agitation rate can be altered according to thesensed size of the load. In the present invention, the load size isdetermined regardless of the types of fabric materials contained in theload. As well, in certain load conditions such as large loads, thedeepfill portion may be slightly altered in order to optimize andmaximize the wash performance. This may be performed not only as aresult of detecting the load size but also as a result of user controlinputs.

[0010] Furthermore, the control may be used to detect specialconditions, for example unusually wet laundry at the outset of the washcycle or failure in some aspect of the wash cycle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a perspective view of a partially cut away automaticwasher containing recirculation hardware embodying the principles of thepresent invention.

[0012]FIG. 2 is a schematic diagram of an automatic washer portraying influid circuit form the recirculation hardware and control arrangementembodying the principles of the present invention.

[0013]FIG. 3 is a block diagram of the process for controlling the spraypretreatment portion of the wash cycle based on monitoring the conditionof suds lock occurrence.

[0014]FIG. 4a is a block diagram of an automatic washer containingrecirculation hardware using flow rate information to control the amountof water added during the spray pretreatment portion of the wash cycle.

[0015]FIG. 4b is a block diagram of an automatic washer containingrecirculation hardware using height of water in the tub sump informationto control the amount of water added during the spray pretreatmentportion of the wash cycle.

[0016]FIG. 5 is a plot displaying the typical form by which the inletvalve is controlled based on measured information.

[0017]FIG. 6 is a block diagram of the general process for determiningwhether suds lock has occurred based on criteria and suds lock measureinformation.

[0018]FIG. 7 is a block diagram that shows the components which make upthe drive system and the corresponding means for measuring the existenceof suds lock through each component.

[0019]FIG. 8 is a block diagram that shows the measuring of theexistence of suds lock through measuring the height of suds in thetub/basket.

[0020]FIG. 9 is a plot displaying the process by which the inlet valveis controlled based on measured information for the special case ofhaving too much added water in the system at the start of the cycle.

[0021]FIG. 10 is a plot displaying the process by which the inlet valveis controlled based on measure information for the special case of neversatisfying the measure due to some failure condition in the machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] In FIG. 1 a washing machine is generally shown at 10 which has atub 12 with a vertical agitator 14 therein, a water supply 15, a powersupply (not shown), an electrically driven motor 16 operably connectedvia a transmission 20 to the agitator 14 and controls 18 including apresettable sequential control device 22 for use in selectivelyoperating the washing machine 10 through a programmed sequence ofwashing, rinsing and extracting steps. A water level setting control 18is provided for use in conjunction with control device 22. A fullyelectronic control having an electronic display (not shown) may besubstituted for control device 22. The control device 22 is mounted to apanel 24 of a console 26 on the washing machine 10. A rotatable andperforate wash basket 28 is carried within the tub 12 and has an opening36 which is accessible through an openable top lid 30 of the washer 10.Tub ring 37 is positioned overlying wash basket 28 and tub 12.

[0023] The invention disclosed herein is not necessarily limited toimplementation in a vertical axis washing machine as shown in thefigures. Inasmuch as the invention is a washing machine having a uniquecontrol and recirculating spray wash arrangement, the invention may beequally applied in a horizontal or tilted axis washing machine.Moreover, in the specific application of the invention in a verticalaxis washing machine, the invention may be practiced in a variety ofmachines which may include different motor and transmissionarrangements, pumps, recirculation arrangements, agitators or impellers,or controls.

[0024] A sump hose 40 is fluidly connected to a sump (not shown)contained in a lower portion of tub 12 for providing a wash fluidrecirculating source. Pressure dome 42 receives the recirculating fluidwhich exits via recirculating spray nozzle hose 48 which is fluidlyconnected to recirculating spray nozzle 32. A pressure sensor ortransducer 46 detects fluid pressure within pressure dome 42 andprovides an output signal via lines 47 to the control, the signalvarying dependent upon the sensed dynamic pressure. A second air dome 50having a deepfill pressure sensor or transducer optionally provides asecond pressure signal indicating static pressure to the control vialines 52.

[0025] As described herein, a pressure sensor may be a pressure switchhaving predetermined pressure levels that, within certain limits, willprovide one or more signals to control 22 that a certain pressure hasbeen achieved. Depending on the presence or absence of such signals, thecontrol will receive and store or process such information, as is wellknown. Alternatively, a transducer may be used to sense pressure andprovide a signal of varying frequency or voltage to control 22indicating the pressure levels detected.

[0026] In FIG. 2 a schematic diagram further describes an example of awashing machine incorporating the present invention. Hot water inlet 11and cold water inlet 13 are controlled by hot water valve 17 and coldwater valve 19, respectively. Valves 17 and 19 are selectably openableto provide fresh water to feed line 60. A spray nozzle valve 21 isfluidly connected to feed line 60 for selectably providing fresh waterto tub 12 when desired. This fresh water is delivered by fresh waterspray nozzle 31 via fresh water hose 33. Valves 17 and 19 are openableindividually or together to provide a mix of hot and cold water to aselected temperature.

[0027] Upon opening one or both of valves 17 and 19, fresh water isselectably provided to a series of dispenser valves via feed line 60.Valve 62 selectably provides fresh water to detergent dispenser 63,valve 64 selectably provides fresh water to bleach dispenser 65, andvalve 66 selectably provides fresh water to softening agent dispenser67.

[0028] As further shown in FIG. 2, the washing machine includes a washliquid recirculation system. In order to recirculate wash liquid for therecirculating spray wash, tub sump 41 collects wash liquid and isfluidly connected to pump 23 by sump hose 40. Pump 23 is selectablyoperational to pump liquid from tub sump 41 via pump outlet hose 25either to recirculating hose 27 or drain hose 29 depending on theposition of bidirectional valve 30. Recirculating hose 27 providesrecirculating wash liquid to pressure dome 42, the wash liquid exitingthe pressure dome 42 via recirculating spray nozzle hose 48 and beingemitted to the wash basket 28 via recirculating spray nozzle 32.

[0029] Pressure dome 42 provides a head of pressure varying dependentupon the amount of wash liquid contained in the recirculating washsystem by maintaining a captured dome of air in communication with therecirculating wash liquid. The pressure dome 42 provides a channel forthe captured air to keep in contact with pressure sensor 46 via pressureline 45.

[0030] Pressure sensor 46 provides optionally either an on/off or avarying or dynamic signal to control 22 via lines 47, the signal varyingdependent on the sensed pressure of the recirculating wash liquid.Control 22 also optionally receives a static pressure signal fromdeepfill transducer dome 50 via lines 52 for signaling the level of washliquid within wash tub 12, however the invention disclosed herein may bepracticed without use of a deepfill pressure dome. Control 22 is furtheroperable to receive input signals via lines 49, including signals fromvalves 21, 62, 64 and 66 providing on and off times for these valves.

[0031] By sensing the air pressure within pressure dome 42, the amountof recirculating wash liquid in the washing machine may be inferred.This information is useful to determine the amount of free water in thewashing machine during a recirculating wash. Thereby, the amount ofclothing in the washing machine may be inferred, which information isuseful in order to minimize water and energy usage during a spraypretreatment cycle, stain cycle or other recirculating wash cycle, andfurther during later or other portions of the cycle. Also, the suds lockcondition, or absence thereof during portions of a cycle may bedetermined. Suds lock may be prevented by limiting recirculating washliquid to slightly in excess of clothes saturation.

[0032] A basic process for the new control scheme of the spraypretreatment portion of the wash cycle is shown in the block diagram 100in FIG. 3. The process begins at the commencement of spray treatment 102by starting monitoring of the suds lock algorithm 104. The processsimply either completes the full cycle if suds lock does not occur orskips through the rest of the pretreatment cycle and onto the next step106 in the case that suds lock should occur. This process 100 isindependent of the method by which the existence of suds lock isdetermined.

[0033] Several methods can be applied in order to ascertain theexistence of suds lock. FIG. 4a displays a block diagram 108 of theautomatic washer containing recirculation hardware where a measure basedon the flow rate of the wash liquid recirculation line is used toascertain when water is added to the recirculation system. The flow ratecan be measured in one of a number of known ways. A flow washer 68contained in detergent dispenser valve 63 controls the flow rate withina predetermined range for a variety of predictable inlet waterpressures. Limiting flow in this manner allows the flow rate to beinferred based upon the on time of the inlet valve. A flow meter mayalso be used. Finally, the deep fill rate may also be discerned.

[0034] This intermittent process is due to the dry clothes loadabsorbing water into the load and thus the system requiring more waterto regain the necessary flow rate. A similar approach shown in a blockdiagram 110 in FIG. 4b to determine when water needs to be added to thesystem can be performed by any of various techniques capable ofmeasuring the height of the wash fluid in the sump portion of the tub.Alternatively, a pressure sensor may be used to determine whether one ormore predetermined pressure levels have been reached. In either case, ifthe control determines that the necessary wash fluid amountrecirculating within the washer is satisfied, the control discontinuesadding water by intermittent opening of the water inlet valve.

Detecting Load Size During Pretreatment Portion of Cycle

[0035] Using either of these means shown in FIGS. 4a or 4 b to controlthe process of adding water to the system, an alternating pattern of thetimes for the addition of water to the system and not adding water tothe system can be gained. FIG. 5 shows such a typical pattern or profile112 relating to the on and off periods of the inlet valve for the spraypretreatment portion of the automatic wash cycle, based on whether thewater level or water pressure detecting means is satisfied. Preferably,the control determines the necessary amount of wash liquid as thatamount which is slightly in excess of the saturation level for theclothes load.

[0036] Accordingly, as the pretreatment portion of the cycle proceeds asshown in FIG. 5, the control continually monitors the inlet on or offtimes or both on and off times, or the pressure or water level signalswhich are used to control the inlet on, off or on and off times. Thisinformation, as discussed later herein, may be used to determine whetherthe clothes washer is experiencing a suds lock condition or some otherabnormal condition if the information is outside a certain expectedrange. As well, however, this information may be used to determine theload size being washed, so that the pretreatment cycle and laterportions of the wash cycle may be altered and preferably optimized oradapted to effectively complete the cleaning and rinsing of the clothes,but no more in order to avoid suds lock.

Pretreatment Cycle Control Based on Load Size Measurement

[0037] By using the measure of load size during the pretreatment cycle,the rest of the pretreatment cycle can be optimized based on the loadsize information. After the desired water level or pressure is detectedas initially satisfied by the control 22, the washing machine is allowedto continue the normal pretreatment cycle where water is added to thesystem as requested by the control system for a first predeterminedtime. The control then identifies the load size in a manner aspreviously discussed. The inlet valve may be shut off regardless ofwhether water is called for by the control system when a secondpredetermined time is reached. This second predetermined time may bedefined based on the load size measure. At this time, the pretreatmentstep is completed and the machine proceeds through the rest of thecycle. The process of not adding water will aid the system in avoidingsuds lock which increases the performance of the cycle.

[0038] In another example of optimizing the rest of the pretreatmentcycle based on the load size information, the control system determinesthe total water fill times at preselected intervals. Depending on thetotal water fill time, a preselected overall cycle time for pretreatmentis performed, during which water may be added. The cycle is furtheroptimized by taking into consideration the water level and cycleselected by the user, so that the washer may perform not only accordingto the load size detected but in accordance with the demands of theuser.

Total Cycle Control based on Load Size Measurement

[0039] From the various means of determining load size during thepretreatment portion of the cycle, this information can be applied tocontrol other portions of the cycle. In previous washers, the load sizeor water level input on the console is the input used to control theamount of water added to the system in the deep fill and the relativeagitation rate based on the type of cycle chosen. In the presentinvention, the load size determined from the pretreatment step can beapplied in a similar way to determine water amounts and control theagitation performed during the rest of the wash cycle. For example, theload size information can be used to determine the agitation length andrate, to determine the deep fill wash length, spin time and speed, thedeep fill or spray rinse length, spin time and speed, or the number ofrinses.

[0040] An automatic washer incorporating the present invention maypreferably include traditional user control inputs such as cycle, watertemperature and water level. Although the input by the consumer may betaken into consideration to affect the cleaning cycle, the controlselectively processes the previously mentioned inlet on, off or on andoff, water level or pressure information independently of such userinput to determine the size of the clothes load. It is noted that thetype of clothes, particularly the variety of materials providing themakeup of the clothes is not of critical importance once thepretreatment cycle is completed, since the load size information gainedduring the pretreatment cycle is all that is needed to continue the washprocess. However, the user input may be considered as part of analgorithm such that the performance of the washer, for example thelength of wash time, is not greatly different than consumer expectationsfor a selected input.

[0041] In another example of optimizing the rest of the wash cycle basedon detected load size, it is a known problem in a vertical axis washerto turn over a large clothes load approaching 17 pounds during a deepfill wash. One difficulty is that after filling the washer to themaximum level and beginning agitation, the large items in the load suchas sheets, tablecloths or towels may be displaced above the waterline bythe agitator, which physically lowers the water level in the tub. Thelowering of the water level in the tub can be anticipated by control 22or detected via a pressure sensor 46 or 50 and compensated for by addingwater to return to the maximum level.

[0042] Alternatively, to address the aforementioned problem, a delayedfill may be used. When the user selects a heavy duty cycle along withmaximum water level, for example the water level in the deep fill washis initially brought to a level slightly below the maximum. The clothesload will be partially submerged, with a portion of the load remainingdry or at most partially saturated on the surface. At this water level,the agitator is allowed to commence turning and will easily pull the dryclothing from the top of the load, moving the clothes down the center ofthe basket and up the outside in the normal motion. After an initialpreselected period, long enough to allow the load to be fully wetted andlargely submerged, the washing machine may be filled to the maximumlevel followed by additional agitation or while continuing to agitate.The preceding process assures that normal rollover of the wash load isachieved as quickly as possible despite the large load.

Suds Lock Measuring

[0043]FIG. 6 displays a block diagram 118 of the general process fordetermining whether suds lock has occurred based on selected criteriaand suds lock measure information. This diagram is independent of chosenmeasurement technique. Several sets of criteria are satisfactory for thecase of using information about the inlet water valve cyclinginformation measurement of suds lock. The following table containsseveral functional criteria: TABLE Suds Lock Criteria Table for InletWater Valve Based Measures. Suds Lock Measure Suds Lock Criteria Case(1) t_(on)(0) 10-20 sec. Case (2) t_(on)(0)/(t_(on)(1)) N Case (3)t_(on)(0)/(t_(on)(1) + t_(on)(2)) N Case (4) t_(on)(0)/(t_(on)(1) +t_(on)(2) + t_(on)(3)) N

[0044] As part of the suds lock criteria, note that if t_(on)(2),t_(on)(3)=0, then let t_(on)(2)=t_(on)(3)=t_(on)(1). The optimum valuefor N is approximately 2. The algorithm also incorporates a minimumtime, t_(min) _(—) _(check), which to start checking for suds lock tooccur. This time could be set between 0 sec and 40 sec. In addition tosatisfying the suds lock criteria, there also is a time t_(on) _(—)_(min) which sets a minimum time of addition which it must be above tobe considered as suds lock condition. Typical ranges for this arebetween 2 to 4 sec.

[0045] Other ways exist for detecting suds lock in the washing machine.FIG. 7 displays a block diagram 120 that shows the components which makeup the drive system and the corresponding means for detecting theexistence of suds lock through each component. For the basket, the meansfor detecting the existence of suds lock 122 may be summarized asfollows.

[0046] A first suds lock detection method is by measurement of thebasket RPM (by magnetic, optical or ultrasonic means) after the basketis brought up to normal operating speed. When basket reduces RPM by 70 %from the steady state value, suds lock has occurred.

[0047] A second suds lock detection method is by measurement of thebasket or tub acceleration after the basket is brought up to normaloperating speed. Vibration of the basket or tub should be fairlyconstant or increasing during the spray pretreatment portion of thecycle unless suds lock occurs.

[0048] For the drive system, the means for detecting the existence ofsuds lock 124 may be summarized as follows.

[0049] A first suds lock detection method is by measuring thetemperature of the clutch. When a suds lock condition occurs, thetemperature of the clutch will increase significantly during suds lockcondition. A second suds lock detection method is by measuring torque ondrive components. When a suds lock condition occurs, a significant dropin torque will occur.

[0050] For the motor, motor control and supply power, the means fordetecting the existence of suds lock 126, 128 and 129 may be summarizedas follows. A first suds lock detection method is by measurement ofmotor RPM using a tachometer which is built into the motor. When thebasket reduces RPM by 70 % from steady state value, suds lock hasoccurred. A second suds lock detection method is by measurement of thecurrent or wattage going to the motor measured at motor. When current orwattage increase by a given percentage, suds lock has occurred.

[0051] A third suds lock detection method is by measurement of totalcurrent or wattage going to the entire machine, since motor current isby far most significant component. When current or wattage increase by agiven percentage, suds lock has occurred. A fourth suds lock detectionmethod is by measurement using an opto coupler for obtaining informationabout drop in the torque draw of the motor. A fifth suds lock detectionmethod is by measurement using a ferrite core sensor for obtaininginformation about the drop in the torque draw of the motor. In thelatter two methods, when torque drops by a given amount, suds lock hasoccurred.

[0052] In addition to measurements which can be made on the drivesystem, measurement of the height of the suds in the system can be made.FIG. 8 displays a block diagram 130 illustrating the components whichare to be observed, that is the tub or the basket, and the means fordetecting the existence of suds lock through each component. Specificembodiments of such techniques to measure the height of the suds duringa spray pretreatment portion of the wash cycle may include a) providinga conductivity strip along the side of the basket; b) ultrasonicmeasurement, or c) optical measurement. Feedback provided to the controlin each case indicates an oversuds condition, from which it may beinferred that suds lock has occurred.

Special Conditions

[0053] In addition to the occurrence of suds lock, there are a fewspecial conditions which can as be detected by the control. Althoughother detection means may be used, in these examples the controlmonitors the inlet valve on time over a prescribed check time. One suchcondition occurs when the machine is started in pretreatment portion ofthe cycle with much more water than necessary. FIG. 9 displays theprocess by which the inlet valve is controlled based on measureinformation for the special case of having too much added water in thesystem at the start of the cycle. This condition can occur for thereasons that the user starts the machine into normal deepfill (withoutprefill), then stops the machine after a good amount of water has filledthe machine (over 2 gallons) and the machine is switched and restartedin pretreatment cycle; the user puts a very soggy clothes load into themachine or the user physically adds water into the machine with theload.

[0054] For all these conditions, the time by which the machine calls forwater will be very small. Thus by monitoring the time by which thecontrol system calls for water with respect to some length of checkingtime, this condition can be ascertained. If such a case should occur,the pretreatment cycle may be ended and the rest of the cycle iscontinued.

[0055] Another special condition can be detected by the primary means ofmonitoring the inlet valve on time over a prescribed check time. Onesuch condition may occur when the washing machine is in therecirculating spray pretreatment portion of the cycle and the machinecontinuously calls for water without stopping.

[0056]FIG. 10 displays a graphic depiction 140 of the process by whichthe inlet valve is controlled based on measured information in thespecial case where the recirculation flow in the system at the start ofthe cycle is not satisfied for some finite period of time. In additionto sensing this condition based on the recirculation flow being notsatisfied, additional information can be gained from the deepfillpressure transducer for the air dome 50 in the tub.

[0057] For the case where the deepfill pressure transducer does notsense the existence of a sizable amount of water in the tub, a varietyof machine conditions may be a cause. Under the category of washingmachine component failures, the failures can include a sizable leak inthe tub or the recirculation or drain hose system; one or more bad inletvalves not adding water to system, or a recirculation diverter valvefailed or stuck in the drain direction. Under the category ofnon-washing machine component failures might be a long fill due to verylow line pressure.

[0058] For the case where the deepfill pressure transducer is sensingthe existence of a sizable amount of water in the tub, the followingmachine conditions may be a cause, all of which are washing machinecomponent failures. The failures can include a bad recirculationpressure switch, a pump or motor failure, a severe recirculation lineclog or the recirculation pressure hose is disconnected.

[0059] In case of such failure, the control 22 will end the cycle andindicate the failure condition to the consumer.

[0060] As is apparent from the foregoing specification, the invention issusceptible of being embodied with various alterations and modificationswhich may differ particularly from those that have been described in thepreceding specification and description. It should be understood that wewish to embody within the scope of the patent warranted hereon all suchmodifications as reasonably and properly come within the scope of thecontribution to the art.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A washing machineapparatus for washing a textile wash load having a wash tub forreceiving a wash liquid within which there is a rotatable wash zoneincluding a peripheral wall, a motor for rotating said peripheral walland said wash load in said wash zone about a predetermined axis and arecirculating wash liquid apparatus for recirculating wash liquid fromsaid wash tub to said wash load comprising: A detection device fordetecting the suds condition of said wash liquid and outputting asignal; A control for receiving said signal and outputting predeterminedcommands for washing said fabric items, Said control including apredetermined command for providing a pretreatment step for said washload, all or a portion of said pretreatment step being alterable orterminable by said control upon said control receiving a signalindicating a existing or potential suds lock condition.
 2. A washingmachine apparatus according to claim 1 wherein said detection devicecomprises a pressure detection device for determining the pressure levelof the wash liquid within the recirculating wash liquid apparatus andsignaling said control when pressure changes beyond one or more presetindicated values to indicate suds lock.
 3. A washing machine apparatusaccording to claim 1 wherein said detection device comprises a devicefor measuring the basket speed for determining the speed of the basketand signaling said control when said speed changes beyond one or morepreset indicated values to indicate suds lock.
 4. A washing machineapparatus according to claim 1 wherein said detection device comprises adevice for measuring basket acceleration after the basket is brought upto normal operating spin speed for determining the acceleration of thebasket and signaling said control when said acceleration changes beyondone or more preset indicated values to indicate suds lock.
 5. A washingmachine apparatus according to claim 1 wherein said detection devicecomprises a device for measuring clutch temperature for determining thetemperature of the clutch and signaling said control when said clutchtemperature changes beyond one or more preset indicated values toindicate suds lock.
 6. A washing machine apparatus according to claim 1wherein said detection device comprises a tachometer for determining thespeed of the motor and signaling said control when said motor speedchanges beyond one or more preset indicated values to indicate sudslock.
 7. A washing machine apparatus according to claim 1 wherein saiddetection device comprises a device for measuring either current orwattage for determining the current or wattage provided to the motor andsignaling said control when said current or wattage changes beyond oneor more preset indicated values to indicate or predict suds lock.
 8. Awashing machine apparatus according to claim 1 wherein said detectiondevice comprises a device for measuring either current or wattage fordetermining the current or wattage provided to the washing machine andsignaling said control when said current or wattage changes beyond oneor more preset indicated values to indicate or predict suds lock.
 9. Awashing machine apparatus according to claim 1 wherein said detectiondevice comprises a device for measuring motor torque for determining andsignaling said control when said motor torque changes beyond one or morepreset indicated values to indicate or predict suds lock.
 10. A washingmachine apparatus according to claim 1 wherein said detection devicecomprises a device for measuring the level of suds within said washingmachine and providing a signal to said control upon measuring apredetermined suds level.
 11. A washing machine according to claim 10wherein said device is a conductivity strip.
 12. A washing machineaccording to claim 10 wherein said device is an ultrasonic emitting anddetecting device.
 13. A washing machine according to claim 10 whereinsaid device is a light emitting and detecting device.
 14. A washingmachine apparatus for washing a textile wash load having a wash tub forreceiving a wash liquid within which there is a rotatable wash zoneincluding a peripheral wall, a motor for rotating said peripheral walland said wash load in said wash zone about a predetermined axis and anapparatus for recirculating wash liquid from said wash tub to said washload comprising: a control for outputting predetermined commands forwashing said fabric items, selectably controlling the on, off or on andoff states of one or more inlet valves and receiving information aboutthe on, off or on and off states of said valves; said control includinga predetermined command for providing a pretreatment step for said washload, said control being programmed to issue a command upon said controlreceiving one or more signals indicating that said inlet valves havebeen on, off or a combination of on and off a predetermined timeindicating suds lock or an abnormal condition.
 15. A washing machineaccording to claim 14 wherein said issued command is a command toterminate a portion of said pretreatment step.
 16. A washing machineaccording to claim 14 wherein said issued command is a command todiscontinue adding water to said washing machine.
 17. A washing machineapparatus for washing a textile wash load having a wash tub forreceiving a wash liquid within which there is a rotatable wash zoneincluding a peripheral wall, a motor for rotating said peripheral walland said wash load in said wash zone about a predetermined axis and arecirculating wash liquid apparatus for recirculating wash liquid fromsaid wash tub to said wash load comprising: A sensor located in saidwashing machine for detecting amounts of recirculating liquid andproviding corresponding signals, A control having a preprogrammedinformation processor for receiving said signals and consumer input andoutputting predetermined commands comprising a cycle for washing saidfabric items, Said control having an initial cycle comprising additionof water and providing a combined spray and spin, said initial cyclehaving a portion for determining the size of the fabric load.
 18. Anautomatic washer according to claim 17 wherein said control determinesthe size of said fabric load based on information provided by saidsensor.
 19. An automatic washer according to claim 18 wherein saidsensor is a pressure sensor.
 20. An automatic washer according to claim17 wherein said cycle is altered by said control using said fabric loadinformation.
 21. An automatic washer according to claim 17 furtherincluding an inlet valve, wherein said control determines the size ofsaid fabric load using information about the on, off or on and off stateof the inlet valve.
 22. An automatic washer according to claim 17wherein said cycle is altered by said control using said fabric loadinformation, said control considering said consumer input.
 23. Anautomatic washer according to claim 21 wherein said cycle is altered bysaid control using said fabric load information, said controlconsidering said consumer input.
 24. An automatic washer according toclaim 17 further including one or more deep fill wash cycles followingsaid initial cycle, said deep fill wash cycles including one or moreperiods of fabric load agitation, drain and spin, followed by one ormore deep or spray rinse cycles including one or more periods of fabricload agitation, drain and spin, wherein said determined load sizeinformation is used by said control to affect one or more portions ofsaid deep fill wash cycles or said deep fill or spray rinse cycles. 25.A washing machine comprising: an imperforate wash tub, a wash basketpositioned within said wash tub defining a wash zone, a fresh waterinlet and a recirculation system comprising a collection zone forreceiving wash liquid from said wash zone and being spaced below saidwash basket, a pump having a suction inlet communicating via a firstfluid conduit with said collection zone and a discharge outletcommunicating with a recirculation nozzle via a second fluid conduit,said nozzle being positioned to direct wash fluid into said wash zone, apressure dome located in fluid connection with said pump dischargeoutlet and having a pressure detection device for detecting the sudscondition of said wash liquid by determining the pressure level of thewash liquid within the second fluid conduit and outputting a pressuredetection signal and a control for receiving said pressure detectionsignal and outputting predetermined commands for washing fabric items.26. A washing machine according to claim 25 where in the case saidpressure detection device detects a failure situation where the desiredrecirculation is not satisfied, said control providing a predeterminedcommand for terminating all or a portion of the cycle.
 27. A washingmachine according to claim 25 where in the case said pressure detectiondevice detects a failure situation where suds lock exists, the controlprovides a predetermined command for terminating the pretreatment step.28. A washing machine according to claim 25 where said pressuredetection device detects load size during the pretreatment cycle andsaid control provides a predetermined command to perform a predeterminedseries of steps.
 29. A washing machine according to claim 25 where saidcontrol detects load size based on detected inlet on, off or on and offtime information.
 30. A washing machine according to claim 25 where saidcontrol prevents occurrence of suds lock based on detected inlet on, offor on and off time based on said pressure sensor signaling said controlto add water.
 31. A washing machine according to claim 25 where saidcontrol determines the length of the pretreatment portion of the cyclebased on the detected load size information.
 32. A washing machineaccording to claim 25 where said control controls cycle processes basedon load size information either obtained from a user interface ormeasured during pretreatment cycle.
 33. A washing machine apparatus forwashing a textile wash load having a wash tub for receiving a washliquid within which there is a rotatable wash zone including aperipheral wall, a motor for rotating said peripheral wall and said washload in said wash zone about a generally vertical axis and an agitatoror impeller for imparting energy to said wash load to cause rollover ofsaid wash load comprising: A control for receiving user input andoutputting predetermined commands for washing said fabric items, Saidcontrol including a predetermined command where upon selection of apredetermined high water level or detection of a large load, saidcontrol provides for a delayed deep fill wash including a first fill toa first predetermined level, soak, agitation or both of the load for afirst period to assist rollover followed by a second fill within saidwash tub to a higher water level.
 34. A washing machine according toclaim 34 where said control performs said delayed deep fill wash uponconsumer input to said control selecting a maximum water level.
 35. Awashing machine according to claim 34 where said control performs saiddelayed deep fill wash upon consumer input to said control selecting aparticular cycle.